Implemented Data-Driven Automation and Sustainability for a Global Chemical Manufacturer
Overview
Thailand’s leading eco-friendly chemical enterprise sought to modernize its packaging operations by streamlining data collection processes and gaining insights into efficiency, utilization, and power consumption across its global plants. ACL Digital was pivotal in automating data workflows, replacing manual data entry across 300+ worksheets with an advanced Azure-driven data lake. The objective was to provide a comprehensive 360-degree view of key performance indicators (KPIs) and trend analysis from the country level down to individual machines, molds, and cavities.
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Challenges
Data Unification and Standardization
The company needed to standardize data capture processes across multiple plants, ensuring uniformity and consistency
Lack of Design Documentation
No Business Requirement Document (BRD) or comprehensive design was in place, making collaboration and development challenging
Complexity in Business Calculations
The company relied on numerous Excel-based micro-calculations that required refinement and integration into a new automated system
Multiphase Implementation
Each solution had to pass through research, demo, development, implementation, and training phases, requiring meticulous attention to detail
Granular Insights
The company required detailed insights into plant efficiency, utilization, and power consumption across machines, molds, and cavities to optimize operations and reduce waste
Solution
- Manual File Optimization: Initial steps included manually correcting existing file structures, designing efficient layouts, and identifying essential KPIs and formulas.
- Data Fabric Construction: ACL Digital developed a versatile data fabric capable of collecting structured, semi-structured, and unstructured data from multiple sources.
- Agile Development Approach: Following an agile methodology, ACL Digital extracted, validated, and refined formulas iteratively, ensuring accurate and insightful reporting.
- Interactive Dashboards: The team designed dynamic dashboards and widgets that allowed users to pinpoint inefficiencies and losses and highlight critical KPIs across all operational levels.
- Comprehensive Insights: ACL Digital generated detailed insights into efficiency, utilization, and power consumption, allowing the company to monitor performance from the country level to individual machine cavities.
Outcomes
Azure-Driven Data Landscape
Standardized Data Capture
Data validation and capture processes were enhanced and standardized, resulting in nearly 100% accuracy across all plants
Operational Visibility
The company gained unparalleled visibility into unit efficiency, utilization, and power consumption, enabling more informed decision-making
Business Optimization
The new dashboards helped identify revenue leaks, refine cost models, and optimize raw material usage, improving operational efficiency and sustainability
